contitech energy projects_arya dash

ENERGY PROJECTS PROPOSAL FOR CONTITECH, WIGAN

September 13

2013

ARYA DASH

ENERGY ANALYST, CONTITECH WIGAN THE UNIVERSITY OF MANCHESTER

2 ENERGY PROJECTS PROPOSAL FOR CONTITECH, WIGAN

Prepared By: ARYA DASH

Acknowledgement

I have taken efforts in this project. However, it would not have been possible without the kind support and help of many individuals and organizations. I would like to extend my sincere thanks to all of them.

I am highly indebted to Mr. Matthew Egeland for his guidance and constant supervision as well as for providing necessary information regarding the project & also for their support in completing the project. I would like to express my gratitude towards the members of Contitech, Wigan for their kind co-operation and encouragement which help me in completion of this project. I would like to express my special gratitude and thanks to Mr Ian Jones, Mr Andreas Qual and all other industry persons for giving me such attention and time. My thanks and appreciations also go to Mr. Paul Snellgrove, Mr. Gary Heard, Mr. Stephen Hamlett, Mr. Martin Atkins, Mr. Barry Unsworth, Mr. Neil Stout, Mr. Philip Sheeran, Mr. Malcolm Smethurs, Mr. Dan McCloughlin and Mr. Simon Pykette who have willingly helped me out with their abilities.



Table of Contents ABSTRACT ...................................................................................................................................................... 4

INTRODUCTION TO CONTITECH’S GAS INFRASTRUCTURE: .......................................................................... 8

ISSUES: .......................................................................................................................................................... 9

TURNING BOILER INTO PROFITS: ................................................................................................................ 11

RECOVERY FROM THE CONDENSATE: ..................................................................................................... 12

CONTROLLING THE BOILER FEEDWATER TDS: ........................................................................................ 20

HEAT RECOVERY (from TDS only) ........................................................................................................... 29

IMPLEMENTATION OF A GAS MANAGEMENT SYSTEM: ............................................................................. 39

SWITCHING THE SPACE HEATERS FROM HP TO LP: .................................................................................... 45

REVIEW OF THE ISSUES AND RECOMMENDATIONS: .................................................................................. 49

INTRODUCTION TO THE LIGHTING AT CONTITECH:.................................................................................... 57

LIGHTING ACTION PLAN .............................................................................................................................. 59

KNX BUILDING AUTOMATION ..................................................................................................................... 63

WHAT IS KNX? ......................................................................................................................................... 63

WHAT ARE WE AFTER? ANSWER- ETS 4 PROFESSIONAL: ....................................................................... 64

LINKING THE EXISTING LIGHTING INFRASTUCTURE TO THE EMS ............................................................... 68

OPERATION: ............................................................................................................................................ 69

SAVINGS: ................................................................................................................................................. 70

AMELIORATING PROFITS:........................................................................................................................ 71

CONCLUSION: .............................................................................................................................................. 72

APPENDICES ................................................................................................................................................ 73

BIBLIOGRAPHY ............................................................................................................................................ 74



ABSTRACT

The gas consumption of the Wigan site has lead to horrendous bills thereby

diminishing the company’s revenue. Analyses reveal that we have been paying

about £370,000 on an average towards our gas bills every year which is 160% of

what a unit of this size should be paying. There have been numerous attempts at

reducing this ‘horrendous’ consumption in the past, but this has only aggrandised

the problem rather than actually solving it.

(Christian and Gallope 1987 as cited by Wikipedia)

With the fuel prices soaring each year, the need for efficient means of energy

reductions has increased. This not only reduces the company’s expenses on

utility, but also counts towards the company’s branding. Even if the cost of

implementations may be high, the profits reaped are high as well. Nevertheless,

there is also a chance of offsetting the investment costs through tax allowances, if

chased up with the government.

More recently, the introduction of the Carbon Reduction Commitment, or CRC,

has compelled businesses to report their carbon footprint and agree to take

action to reduce CO2 emissions or face additional costs by way of penalties or the

requirement to purchase Carbon Credits.

In addition to the savings benefits of acting on energy consumption, there are

some Government incentives, for example, qualifying equipment purchased by

companies to reduce energy consumption can attract Enhanced Capital

Allowances (ECAs). ECAs are a straight forward way for a business to improve its

cash flow through accelerated tax relief. The ECA scheme for energy-saving

technologies encourages businesses to invest in energy-saving plant or

machinery. Such equipment must be specified on the Energy Technology List

(ETL) which is managed by the Carbon Trust on behalf of the Government.

(Carbon Reduction Commitment, Business Green, 2013)



Following the analysis of the gas infrastructure en-site, the key issues spotted

have been outlined first. Identifying the scope of improvements, some projects

have been proposed in this report aimed at reducing the energy consumption of

the site; hence, abate a part of the gas bills. The projects are focused on drawing

maximum benefits through minimum investments. To wind it up, ingenious

endeavours have been made to mitigate all the issues but in the interim all the

projects have been challenged against feasibility and company’s prospects and a

final suggestion of suitable ‘quick fix projects’ has been summarised at the end.

A recent survey by ‘Ex-or’ claims that ‘85% of the companies waste unnecessary

cash on lighting’. According to the data, on an average, lighting is left on in the

workplace for up to 12 hours a day unnecessarily – including in storerooms and

warehouses. Just under a quarter (17 per cent) of those polled responded that

their office lighting is sometimes needlessly left on for up to 24 hours a day.

Furthermore, Ex-Or’s survey found that a staggering 44 per cent of respondents

indicate that up to five unoccupied rooms at their workplace are left lit for

significant portions of the day and nearly one in five admitted more than 20

rooms are lit unnecessarily.

(Exor Survey shows 85% of the companies waste unnecessary cash on lighting,

Honeywell Press Release)

Statistics published by the Department of Energy and Climate Change (UK, July

2011) show that across a broad selection of non-domestic applications, lighting

represents, on average, 21 per cent of a building’s total energy consumption.

While some companies are taking steps to become more responsible others need

to make moves or risk missing out on potential bottom line savings and increased

energy efficiency.

(Electricity Market Reform: keeping the lights on in the cheapest, cleanest way, 12

July 2011, Department of Energy and Climate Change, GOV.UK)



If we simplify the statistical info from ‘GOV.uk’ for Contitech, Wigan, we are

talking an average annual spent of about £170,000 on lighting itself, and hence,

‘lowly’ fall into the 85% of the companies that fail to control their site’s lighting.

So, endeavours have been made in this report to abate this grand spent on

lighting which makes more economic, political and social sense.

Due to the paucity of time, only an outline of what could be accomplished with

the technology available has been provided. Wholly, two proposals have been

made to abate costs on lighting. The first one proposes the installation of a ‘full-

fledged Building Management System’ whereas the latter one entails enhanced

profits through incorporating the lighting infrastructure with the ‘Vickers Gas

Management System’.

The ‘Gas’ has been dealt with first following the correction of the ‘Contitech

Wigan Gas Spreadsheet’ as an attempt to make the most of the fresh findings on

the gas infrastructure; lighting follows.



GAS PROJECTS



INTRODUCTION TO CONTITECH’S GAS INFRASTRUCTURE:

The Wigan plant is a 1950s building and back then, not much attention was paid

to the amount of energy being used. The current gas infrastructure comprises of a

‘High Pressure’ (from here on, called HP) and a ‘Low Pressure’ (from here on,

called LP) system. The former serves 16 space heaters which are labelled under

Conti East and Conti West and also a 10,000 lb/hr ‘boiler’ where as the latter

serves the lone heater in the kitchen. The site’s total kW rating is 1,536 kW which

equates to 144m^3/hour in terms of flow rate. The gas to Contitech is supplied

via a 100mm main with 50mm branches to each area, reducing the size as it

makes its way through the factory. A more detailed overview has been enclosed

in the appendices section.

(Gas Flow Rates Survey at Contitech Wigan, Techniheat Plant Services Ltd)



ISSUES:

After closely working with the ‘Maintenance’ and analysing the gas infrastructure

of the site, many issues were spotted those drive high consumption. These have

been outlined below:

All the space heaters are on HP :

The space heaters need about 25 millibars to work which is LP. But they are

installed on the HP line (i.e. 175 millibars). The HP flow is then reduced to

LP through a different pipe work and the flow rate is maintained by some

sort of controls on the heaters. This is a major issue because HP has a

correction factor roughly as big as 200% of LP. In crude terms, we pay thrice

the amount for the same amount of gas used. After interrogation with the

maintenance, I found out that the reasoning behind this sort of maladroit

layout was tenuous.

Inefficient Heat Recovery from the boiler:

Boiler is the biggest beast on the HP system which means most of the

consumption on the HP line comes from the boiler. So, the need of

ameliorating the heat recovery from the boiler becomes pertinent. This

helps in abating the energy demands of the boiler that is synonymous to

saving pounds. A detailed analysis that follows reveals that our boiler only

recovers 19% of the flash steam. But the good news is with the current

technology we could recover up to 90% of the total blowdown energy. It

may sound ‘too grandiose’ at this point but will soon become pragmatic.

Poor Spatial Orientations of Heaters:

The factory was turned around during 2009 to meliorate the financial and

management benefits by reducing double handling costs, improved flow of

processes and logistics. As a follow up to this, the positioning of the heaters

needed to be revised for efficient heating but again due to some trivial

reasons, this wasn’t done. As a consequence to which the heaters have to

be operated for longer hours to reach the set temperature demand thereby

surging the bills.



Improper management:

Even though there is some sort of manual control for the space heating, it’s

increasingly ignored. The heaters are kept on at all times during the winter

months. The bills could be reduced through proper management of all the

space heaters by a considerable amount by having a Building Management

System (BMS) en-site which could link all the space heaters to a single

control unit.

Poor Insulation:

Due to poor insulation in certain parts of the factory, we lose some of the

heat into the atmosphere as a consequence of which the heaters need to

run for longer hours in the corresponding parts.

A comparative study suggests that the first two are significant contributors

to the bills and the latter ones being trivial. So, numerous projects have

been proposed in the later sections including the technical calculation,

payback period analysis and final suggestions aimed at reducing the gas

consumption. The ‘Boiler’ has been considered first as it is expected to bear

huge savings. Then follow the pipelines and ‘Gas Management System’.



TURNING BOILER INTO PROFITS:

Statistically speaking, the boiler contributes to the most of the consumption on

the HP line in this facility. Statistics reveal that the boiler comprises of at least

81% of the total HP supply. In the summer months, this ratio alleviates to nearly

95%. Hence, it is worthwhile making efforts trying to reduce this antagonistic

ratio. It’ll soon become apparent that the investments on the boiler are worth it.

Based on the compatibility with the business, the payback period restrictions and

investment, three highly economical projects have been outlined below in the

decreasing order of their savings.

(Steingress et al.2003)

N.B.-The following is a technical topic. Even though you don’t need to be

technical savvy, a good knowledge of thermodynamics is essential to

understand the underlying calculations. However, care has been taken to keep

it facile and appendices have been attached for better understanding.



RECOVERY FROM THE CONDENSATE:

Theory:

When a kilogram of steam condenses completely, a kilogram of condensate

is formed at the same pressure and temperature (Figure 1.1). An efficient

steam system will reuse this condensate. Failure to reclaim and reuse

condensate makes no financial, technical or environmental sense.

Fig. 1.1- 1 kg of steam condenses completely to 1 kg of condensate Saturated steam used for heating gives up its latent heat (enthalpy of evaporation), which is a large proportion of the total heat it contains. The remainder of the heat in the steam is retained in the condensate as sensible heat (enthalpy of water) (Figure 1.2).

Fig. 1.2- After giving up its latent heat to heat the process, steam turns to

water containing only sensible heat



WHY RECOVER FROM CONDENSATE:

Financial reasons Condensate is a valuable resource and even the recovery of small quantities is often economically justifiable. The discharge from a single steam trap is often worth recovering. Un-recovered condensate must be replaced in the boiler house by cold make-up water with additional costs of water treatment and fuel to heat the water from a lower temperature.

Water charges Any condensate not returned needs to be replaced by make-up water, incurring further water charges from the local water supplier.

Effluent restrictions In the UK for example, water above 43°C cannot be returned to the public sewer by law, because it is detrimental to the environment and may damage earthenware pipes. Condensate above this temperature must be cooled before it is discharged, which may incur extra energy costs. Similar restrictions apply in most countries, and effluent charges and fines may be imposed by water suppliers for non-compliance.

Maximising boiler output Colder boiler feedwater will reduce the steaming rate of the boiler. The lower the feedwater temperature, the more heat, and thus fuel needed to heat the water, thereby leaving less heat to raise steam.

Boiler feedwater quality Condensate is distilled water, which contains almost no total dissolved solids (TDS). Boilers need to be blown down to reduce their concentration of dissolved solids in the boiler water. Returning more condensate to the feedtank reduces the need for blowdown and thus reduces the energy lost from the boiler. (Spirax Sarco, Introduction to Condensate Recovery)



Technical Calculations:

The major issue encountered during this analysis is we don’t record the

condensate pressure or the steam trap pressure in the system which makes it

impracticable to conduct the analysis. So, a parametric estimation has been

drawn from historical data of some of the systems already using condensate

recovery. However, all the relevant working has been shown for guidance.

Calculating the amount of flash steam evaporated from the condensate:

Hot condensate at 7 bar g (‘g’ represents gauge pressure) has a heat content of nearly 721 kJ/kg. When it is released to atmospheric pressure (0 bar g), each kilogram of water can only retain about 419 kJ of heat. The excess energy in each kilogram of the condensate is therefore 721 - 419 = 302 kJ. This excess energy is available to evaporate some of the condensate into steam, the amount evaporated being determined by the proportion of excess heat to the amount of heat required to evaporate water at the lower pressure, which in this example, is the enthalpy of evaporation at atmospheric pressure, 2258 kJ/kg.

The amount of flash steam in the pipe is the most important factor when sizing trap discharge lines. The chart below illustrates the dependence of percentage flash steam upon the pressure on the steam traps.

Say for example, if the pressure on the trap is 4 bar and the flash steam pressure is 0 bar, then the % of flash steam evaporated is 10%. Similarly, given the flash steam and the flash steam pressure, the pressure on the traps can be calculated.



Fig. 1.3- The dependence of percentage flash steam upon the pressure on the steam traps.

The system being considered in this example has the following specs:

Rating- 10,000 kg/h; Efficiency- 0.85

Operation- 8400 h/ year

Raw make up water at 10 C and the temperature of the condensate is 90 C



(Spirax Sarco, Introduction to Condensate)

Assumed costs:

Price per unit (in pence)

Water 61

Gas 1 Effluent 45

Table- 1.4: Assumed prices for cost saving analysis

(Water Supply and Sanitation in England and Wales, 2010)

Fuel Savings:

Each kilogram of condensate not returned to the boiler feedtank must be

replaced by 1 kg of cold make-up water (10°C) that must be heated to the

condensate temperature of 90°C. (ΔT = 80°C).

So, the heat required to increase the temperature of 1 kg of cold make-up water

by 80°C, by using Equation

Where:

Q = Quantity of energy (kJ)

m = Mass of the substance (kg)

cp = Specific heat capacity of the substance (kJ/kg °C)

ΔT = Temperature rise of the substance (°C)

m is unity; ΔT is the difference between the cold water make-up and the temperature of returned condensate; cp is the specific heat of water at 4.19 kJ/kg °C. 1kgx4.19kJ/kg°Cx80°C=335kJ/kg Basing the calculations on an average evaporation rate of 10 000 kg/h, for a plant



in operation 8 400 h/year, the energy required to replace the heat in the make-up water: 10000kg/hx335kJ/kgx8400h/year=28140GJ/year If the average boiler efficiency is 85%, the energy supplied to heat the make-up water is:

With a fuel cost of £2.77/GJ, the value of the energy in the condensate is: Annual fuel cost = 33 106 GJ/year x £2.77/GJ = £91 704

Savings on water:

Water is sold by volume, and the density of water at normal ambient temperature is about 1 000 kg/m. The total amount of water required in one year replacing non-returned condensate is therefore:

So, Annual water cost = 84 000 m/year x £0.61/m = £51 240

Determine the effluent cost The condensate that was not recovered would have to be discharged to waste, and may also be charged by the water authority.

Annual effluent cost = 84000 m/year x £0.45/m = £37 800

P.S.- It must be borne in mind that this is not based on our boiler. So, a parametric analysis is required to account of the difference in the boiler rating and efficiency.

Parametric Analysis:



Using the technical specs provided in the appendices,

The efficiency compensation= 0.75

Actual Steaming rate= 4536 kg/h

Based on these constants, the savings are as follows:

Utility

Potential Savings (£)

Actual Savings (£)

Fuel 91704 31197.7

Water 51240 17431.85

Effluent 37800 12859.56

Total 180744 61489.11

Table 1.5: Parametric Estimation for actual cost savings through condensate

recovery

Clearly we are looking at a minimum savings of about £60,000 provided all the

conditions are ideal.

Payback period:

It is given by-

Where



A more complicated analysis is involved to check if a project is worth investing. It

takes into account the interest rates, ‘Internal Rate of Return’ and ‘Net Present

Value’. However, is not necessary to get into the pedantic details of this analysis

as there is no maintenance cost outlined by the service provider. So, our payback

period analysis is relatively straight forward i.e.

It can be noted that the payback period is well below the threshold of 2 years.

However, the time the system shall take to kick off and perform at its optimal

efficiency needs to be taken into account. Service providers claim that this period

could be about a month.

(Spirax Sarco Quotes, 2011)

Even after considering all the uncertainties, we still have a buffer of at least 30

weeks, which is good news. More importantly, we will be making £61,000 every

year after the moratorium period with no further investments.

N.B.-(i) The investment cost is based upon the referenced contractor quotes

obtained in 2011 and are liable to changes. Hence, a price revision is

recommended close to the time of implementation to conduct a more accurate

cost benefit analysis.

(ii) The prices quoted for per unit of gas and water may be different to what the

company actually pays. However, all the analyses from here on use ratios rather

than actual pricing. Hence, they are more accurate.



(iii)This is a parametric analysis based on data from the ‘Maintenance’. Hence,

the accuracy of the calculation is subject to the accuracy of data provided. The

author holds no responsibility of the accuracy of this particular project as the

information from the maintenance looks dubious.

CONTROLLING THE BOILER FEEDWATER TDS:

The boiler TDS (Total Dissolved Solids) level needs to be closely monitored as it

decides the blowdown rate from the boiler. Controlling the blowdown entails

better control over the heat energy expelled from the boiler. Using some

equations provided in the appendices and thermodynamics, calculations have

been performed to reveal how beneficial controlling the TDS could be both in

terms of maintenance and economics.

To start off the savings analysis, it’s important to estimate our blowdown first.

So, using ,

Where:

F = Feedwater TDS (ppm)

S = Steam generation rate (kg / h)

B = Required boiler water TDS (ppm)

(Pitzer, 1995)

For our boiler,

F= 120 ppm; S= 4536 kg/h and B= 3500 ppm

Substituting the values in the above equation,



This is an important parameter and will be extensively used in the calculations yet

to come.

The role of the controller becomes more pronounced in the next step. Prior to the

calculations, let’s understand what it improves.

Fig. 1.6: Plot of TDS versus time using a manual blowdown 3 times per 24 hours

Where the present method is semi automatic blowdown from the bottom of the boiler, it may be possible by looking at past water treatment records, to obtain some idea of how much the boiler TDS varies over a period of weeks. By inspection, an average TDS figure can be established. Where the actual maximum is less than the maximum allowable figure, the average is as shown. Where the actual maximum exceeds the maximum allowable, the average obtained should be scaled down proportionally, since it is desirable that the maximum allowable TDS figure should never be exceeded.



Fig. 1.7: Plot of TDS versus time using a closed loop electronic TDS control

system

But in real world, the actual operating TDS in the boiler is much below the

maximum allowable. Prior to the savings analysis, calculations have been

performed below to estimate the blowdown in our boiler. The boiler on site is

semi automatic and the average recorded TDS is 1800-2400 ppm (Maintenance)

which isn’t too inefficient, but the upgrades could still save us some cash with a

little or no investment cost if coupled with the heat exchangers and the

‘Condensate Recovery’.

Our TDS Control Performance:

Figure 1.7 shows that the average TDS with a well operated manual bottom blowdown is significantly below the maximum allowable, which is also partly true for a poor performing semi-automatic one. For example the maximum allowable TDS may be 3 500 ppm and the average TDS only 1800 ppm(worst performing condition). This means that the actual blowdown rate is much greater than that required. Based on a feedwater TDS of 120 ppm, the actual blowdown rate is:

(Maintenance)



(Isentropic Flow, Dr Robert Prosser)

We operate at a feed water temperature of 80 C. From steam tables, the = 335

kJ/kg at this static temperature. This temperature needs to be raised to a desired

temperature that could generate enough steam at a set rate.

As can be seen from the appendices,

Our operating pressure in the boiler is 10.6 bar which corresponds to 186.49 C in

the steam table. At this temperature, the latent heat of fusion

which can be obtained from the steam table as well.

(Spirax Sarco, Wet Steam Region- Steam Tables)

The next step is to estimate this energy needed to raise the water at 80 C to the

saturation temperature.

Where:

= latent heat of fusion

S= steaming rate or the boiler rating

Substituting the values provided in the appendices in the above equation:



Now after the feedwater has reached this temperature, it has to outrival the

latent heat of vapourisation to convert itself into steam. For this, we need to

account for the excess energy needed separately.

So,

Improvements through the proposed fully automatic TDS Control:

These systems measure the boiler water conductivity, compare it with a set point, and open a blowdown control valve if the TDS level is too high. A number of different types are on the market which will measure the conductivity either inside the boiler, or in an external sampling chamber which is



purged at regular intervals to obtain a representative sample of boiler water. The actual selection will be dependent upon such factors as boiler type, boiler pressure, and the quantity of water to be blown down. These systems are designed to measure the boiler water conductivity using a conductivity probe.

Fig. 1.8: A closed loop electronic TDS control system

The measured value is compared to a set point programmed into the controller by the user. If the measured value is greater than the set point, the blowdown control valve is opened until the set point is achieved. Typically, the user can also adjust the 'dead-band'.

An increase in water temperature results in an increase in electrical conductivity. Clearly if a boiler is operating over a wide temperature / pressure range, such as when boilers are on night set-back, or even a boiler with a wide burner control band, then compensation is required, since conductivity is the controlling factor.



The benefits of automatic TDS control:

The labour-saving advantages of automation. Closer control of boiler TDS levels. Potential savings from a blowdown heat recovery system (where installed).

Since the technology is expected to match the set TDS closely, actual TDS can be

approximated to the set TDS i.e. 3500 ppm in this case.

So,

Everything from here onwards remains the same. So, carrying forward the

calculations as pervious,

And of course the energy (power) required for steaming remains the same as it

depends on the operating conditions only; which still remain the same.



Savings through this proposal:

Payback Period:

From 2012 gas bills, we can deduce the reduction in bills through this investment.

Calculations reveal that we can abate £4100 (approx) from the existing gas bills.

As quoted by Spirax Sarco, the investment cost of this particular technology is

£2000.

So simply,

As can be seen from above, this technology pays for itself in less than 26 weeks;

which is well below the ‘Continental Regulations’. More importantly, this

technology shall pave the way for the bigger investments which follow; which also

means maximize the benefits drawn from the bigger investments.



On / off boiler blowdown valves: There is an advantage to using a larger control device with larger clearances, but only opening it for some of the time. Clearly, moderation is required if the boiler TDS is to be kept between reasonable values, and DN15 and 20 valves are the most common sizes to be found. A typical arrangement would be to set the controller to open the valve at, for example, 3 000 ppm, then to close the valve at 3 000 - 10% = 2 700 ppm. This would give a good balance between a reasonable sized valve and accurate control. The type of valve selected is also important:

For small boilers with a low blowdown rate and pressures of less than 10 bar g, an appropriately rated solenoid valve will provide a cost-effective solution.

For larger boilers with higher blowdown rates, and certainly on boilers with operating pressures over 10 bar g, a more sophisticated valve is required to take flashing away from the valve seat in order to protect it from damage.

Valves of this type may also have an adjustable stroke to allow the user the flexibility to select a blowdown rate appropriate to the boiler, and any heat recovery equipment being used.



Fig. 1.9

Modern blowdown control valve

(Controlling the boiler TDS, Spirax Sarco)

Finally we move on to the heat exchangers where we could exhaust the actually

potentials of the fully automatic TDS control.

HEAT RECOVERY (from TDS only)

The disposed water has a number of characteristics:

It is dirty - This means that: o The water is generally unsuitable for other applications. o The dirty water may present a disposal problem. It is hot - This means that: o A proportion of the water will flash to steam at atmospheric

pressure. o The hot water may present a disposal problem. For example, there

may be a substantial quantity to dispose of.

A heat recovery system can solve many of these problems. Statistically proven, the condensate recovery has been a very efficient heat recovery technique for boilers and hence, being used widely around the globe. But heat exchangers and



flash vessel which will be discussed here form a major part of the total savings anticipated from the boiler.

N.B. - Good practical knowledge of thermodynamics is needed to follow the calculations as it is beyond the scope of the report to go through the basics of thermodynamics.

From Flash Vessel:

Fig. 1.10- Flash Vessel

From the previous analysis, we have:



Calculated boiler blowdown rate: 161.04 kg/hr= 161.04/36000= 0.045 kg/s

At an operating pressure of 10.6 bar, all the values for the variables those are to loom shortly, have been attached to the appendices.

The makeup water is assumed in to be at 0 C for simplicity of calculations. However around this regime of temperature, the values of enthalpy are not much different and are good enough for a first order approximation.

So,

(From steam tables)

Then,

This may look trivial but is enough to heat 3 British houses! This value however is

slightly less for make up at 10-20 degrees C.

It is then imperative to calculate the percentage of flash steam as this is what our

savings are going to be based on.

(Dr Robert Prosser, Isentropic Flow)

This flash steam is constant for a fixed operating pressure. The LP denotes the

pressure at the flash system where the blowdown water is being released to



which is at 5.17 bar in our facility. And of course, HP denotes the steam pressure

inside the boiler which is 10.6 bar.

(Maintenance)

In order to obtain the corresponding enthalpy values at 5.17 bar, interpolation

was used for better accuracy.

Following that, we get:

So, substituting these values back in the above equation we have

Hence,

To calculate the energy flow rate, use ONLY as the vapour is dry saturated i.e.

dryness fraction is equal to 1.

So far we have only recovered 19% of the blowdown energy. This is everything we

are recovering at the current site. This could be ameliorated to as high as 90% by

amalgamating this with the heat exchangers.



Recovery through heat exchangers:

We know from previous that the total water blowdown= 161.04 kg/h but around

5.6 % of this is steam that has already been recovered. So the rest 94.6% is still

getting wasted. This technology helps us recover about 90% of this blowdown

energy.

Assuming that the water is cooled to 20 degrees C,

The enthalpy of water at 20 C= 84 kJ/kg

(Wikipedia, Enthalpy)

So, simply,

Presuming that the system works perfectly, all this energy can be recovered.

So,

Finally,



Energy savings:

In terms of cash,

Payback period:

Investment cost= £8,000

Savings=£12,000



As can be seen from above, this technology pays for itself in less than 35 weeks;

which is well below the ‘Continental Regulations’. Moreover, this isn’t the lone

investment, which also means this isn’t the lone saving. When all the three

proposals are coupled up, the savings made are ‘great’. This analysis has been

done at the end.

Spirax Sarco Quotes

Equipment required:

Flash vessel - Manufacturers will have sizing charts for vessels. Note: the steam velocity in the top section of the vessel should not exceed 3 m / s.

Steam trap to drain the vessel - A float trap is ideal for this application as it releases the residual blowdown water as soon as it reaches the trap. The flash vessel is working at low pressure so there is virtually no energy to lift the residual blowdown after the steam trap, so this must drain by gravity through the trap and discharge pipe work. Note: because of the low pressure, the trap will be fairly large. This has the additional advantage that it is unlikely to be blocked by the solids in the residual blowdown water. Sometimes strainers are preferred before the steam trap; for this application the strainer cap should be fitted with a blowdown valve to simplify maintenance, and the strainer screen should not be too fine.

Vacuum breaker - There will be occasions when the boiler does not need to blow down. At these times any steam in the flash vessel and associated pipe work will condense and a vacuum will be formed. If this vacuum is not



released then water will be drawn up from the boiler feedtank into the pipe work. When the boiler blows down again this water will be forced along the pipe at high velocity and water hammer will occur. A vacuum breaker fitted to the deareator head will protect against this eventuality.

Steam distribution equipment - Proper distribution of the flash steam in the feedwater tank is clearly important in order to ensure condensation and recovery of the heat and water. The equipment required to do this include, in order of effectiveness:

o Atmospheric deaerator o Steam distributor o Sparge pipe

Fig 1.11- A typical heat recovery circuit with heat exchangers and flash vessel



Design considerations A problem with the arrangement shown above is that the simultaneous flow of incoming cold make-up water and residual blowdown from the flash vessel may not be guaranteed. One preferred arrangement is shown in Figure below, where a cold water break tank is used as a heat sink. A thermostat is used to control a small circulating pump so that when the residual blowdown is at a high enough temperature, water is pumped through the heat exchanger, raising the average tank temperature and saving energy. If the temperature of the blowdown effluent exiting the heat exchanger can be above 43°C, then it should be directed to the blowdown vessel rather than straight to the effluent drain.

Preferred type of heat exchanger Plate heat exchangers are preferred for this application, as they are very compact and easily maintained. Experience shows that the higher velocities and turbulence in plate heat exchangers help to keep them clean, and hence dismantling is rarely required. However, should cleaning be required, it is relatively straightforward to open the heat exchanger and clean the plates. The cleaning of a shell and tube heat exchanger is more complex, and will involve a complete strip down and often the tubes themselves cannot be removed for cleaning.



Fig 1.12 – Heat recovery from TDS with a Cold Water break tank

With an efficient boiler in place, we have already abated at least £75,000 of our

gas bills. However, we could improve this figure through an efficient ‘Energy

Management System’.



IMPLEMENTATION OF A GAS MANAGEMENT SYSTEM:

Advantages of a BMS:

Average cost savings of about 5-6%

CO2 emissions reduced by at least 40 tonnes

Improved reliability through implementation of automation.

Precise monitoring of the energy usage.

Improved operational efficiencies.

Desired quality of the rubber could be preserved under varying weather

conditions.

Due to the paucity of time and resources, the savings analysis has been proposed

for only one GMS, here we analyse ‘Vickers Building Management System’.

Operation:

The ‘Vickers Energy Management System- V42’delivers accurate heating control

for 42 different zones within the building at different times. It does this with

maximum efficiency to reduce energy consumption and subsequently reduce your

energy bills and CO2 emissions.

Fig. 1.13- A typical plan layout



The system’s performance is managed by a central control unit which is

connected to highly accurate digital temperature sensors installed in each area of

your site. The digital sensors are calibrated to ensure 0.1 degree accuracy. These

sensors automatically send information back to the computerised control unit

which immediately calculates the actions required to achieve and maintain the

target temperature in each zone.

The system uses optimisation software to digest all information, including the

internal temperature and external conditions, and calculates how long the

heating will need to be on in order to achieve the desired temperature. In

comparison, a conventional system will be pre-programmed to switch on the

heating at an agreed time every day. This is regardless of other factors like

unpredictable weather and unforeseen events, for example, a door left open. The

same applies in reverse for lowering the temperature when areas are not in use.

(Vickers Electronics, Energy Management System)

All these factors work together to ensure that the heating in any one zone never

goes above your target temperature. This can save you significant money as

confirmed by the Energy Saving Trust who state that, ‘every degree you go over

your target temperature adds 10% to your fuel spend’.

(Know your Gas Bills, Energy Saving Trust)

Technical Information: Components of the System

Synchronous Burner Control This feature modulates the energy input to the heaters to ensure a consistent heat output to meet demand. Unlike conventional controls, it constantly monitors the heat output of every heater and will activate the burner as required to maintain a constant level of heating. Conventional controls will simply keep the burner firing continuously as long as the thermostat is calling for heat.



Optimisation Programme: This is an intuitive programme that calculates the necessary burn time for each heater in your building to achieve the target temperature. As a self-learning tool it requires 2-3 weeks of operation to ‘educate’ itself to the performance of different heaters throughout your site. Once again this ensures that energy is not supplied to any heater for one minute longer than is necessary to achieve the target temperature. The system can also identify how long a heater takes to cool down, so will switch the heater off at the correct time to reduce the temperature when required, such as at the end of the day. Digital Electronic Air Sensors Our Digital Electronic Air Sensors are the very latest in technological design and ensure a high level of accuracy in temperature sensing. They are essential in ensuring that target temperatures are achieved with no surplus energy use. Tamper-proof Controller The tamper-proof controller is at the heart of our system and controls all energy output. It gives you total control over the system but without the risk of conventional controls, which can usually be altered by anyone at anytime, massively affecting energy efficiencies and often leading to waste. Turning a thermostat up by just 1 degree more than necessary has huge implications on cost, as indicated by the Energy Saving Trust who state that ‘every degree you go over your target temperature adds 10% to your fuel spend’. The Vickers control system is safeguarded with a PIN code limiting access to select members of staff only. Following the initial set up, the system can be left to manage and regulate itself. The only times when the system will need re-programming is for major changes in operational pattern such as shift changes. Special access can be given to service engineers as and when required. Our 24 hour help desk can also assist with unplanned changes to shift patterns such as emergency overtime by issuing a ‘first aid’ code to allow additional access to staff to ensure the smooth running of your business 24/7.

(Energy Management System, Vickers Electronics)



Savings through V42:

Even though it’s difficult to estimate the exact amount that could be saved,

efforts have been made to estimate the savings through a savings calculator using

the data provided by the Maintenance. The calculation takes into account the

insulation, the size of the facility, operation hours, number of heaters on site and

statistical information on the amount of energy used. A screenshot of the same

has been provided below:

Fig. 1.14- Savings Calculator from Vickers Electronics

‘Vickers’ promises a reduction of 6% on our energy bills.

Conducting the savings calculations for the whole site for 2012, we have



Hence,

Or potential savings worth £23,000 (approx)

N.B. - But taking into consideration, the nature of usage, poor insulation in certain

parts of the factory and impoverished attempts at improving the space heating, a

buffer of £4,000 has been offered.

Overall Site-2012 Usage(in kWh) 17,358,652

Amount Paid (£) 381,730

Potential Savings 23,000

Actual Savings 19,000

Table 1.15- Savings through Vickers’ BMS

Payback:

In the absence of a contractor quote at the moment, it’s contrary to the point to

conduct a ‘payback period’ analysis. However, an estimated cost from Vickers

electronics has been used for an idea of the potential payback.

Given

So simply,



Vickers also promises free labour and parts guarantee for 24 months and an

upgrade for similar services at a nominal price there on.

(Meeting with Neil Bennet from Vickers Electronics)

So,

Moreover, Vickers also promises to pay back the difference if it fails to meet its

promise. Then why not invest, provided the investment cost fall below the

threshold and they ascertain their promises. The bigger reason to invest has been

cited in the ‘Lighting Section’.



SWITCHING THE SPACE HEATERS FROM HP TO LP:

As addressed at the start, having the space heaters fed from the HP supply is one

of the biggest reasons for getting a horrendous gas bill. In theory, the space

heaters can operate on the LP supply (of 25 millibar) line as they just need about

22 millibars to operate. If the heaters could somehow be planted on the low

pressure line, we could save a fortune.

Savings:

The challenge to conduct this saving analysis is much more daunting than you

may guess. There was no ‘correct’ actual consumption for the space heating. All

the readings were from submeters. Submeters can’t be compared to the mains

and hence, the total of all the HP submeters superseded the total from total HP

consumption (HP mains- what we pay for); which implies that there was in no way

the calculations could be done based on the numbers. Moreover, the numbers

were missing on many occasions. Lack of reference, plenty of erroneous or

missing information on the gas utility spreadsheet and a hallucinatory ‘blackhole’

further impeded it. After investing plenty of time and effort, some trends were

found out based on the utility. Due to the limited scope of the report the

loopholes in the spreadsheet has not been included here but has already been

reported separately in the form of a PowerPoint presentation.

By analysing the spreadsheet for the year 2009 (best set of data was obtained

only for this year), many trends of consumption were found out which remained

almost constant for each year.

And



Since our total HP reading is more than the HP reading of boiler itself, it’s beyond

to the point to compare the numbers. If it were done, it would be called another

‘blackhole’. But, we need the volumes to work out the savings. So, an ingenious

approach was followed to work out the volumes from ratios; which remain

constant throughout; which sort of justifies the accuracy of the analysis involved.

Carrying it forward, the above may be written as:

Substituting values from above, we have:

This gives us 19% savings on corrector usage. But this is NOT equal to 19%

savings on fuel.

As explained previously, year 2009 was used for the analysis.

2009

Total Corrector Value (in meters cu) 366,964

Total LP usage (in cu meters) 216,557

Total Site Usage (in kWh) 11,592,441

Fig 1.16- Site usage in 2009



So, if this 19% reduction in the corrector values is possible,

But this reduction in movement has to be added up to the new LP movement.

Hence,

So,

From above,

Fuel cost is directly proportional to the kWh usage of the site. Hence,

Hence,

In terms of cash savings for 2012,

Total Gas bill for Contitech= £381,730

Hence,



Payback period Analysis:

According to the investment costs quoted in the recent contractor quotes, things

are looking up for this project.

The price quoted was £28,000.

So, simply,

The quote doesn’t account for any additional maintenance costs. So, the payback

becomes:

A buffer of 3- 4 weeks may be given for a more accurate payback period estimate.

N.B.- Even if care has been taken to keep this particular analysis as accurate as

possible, it is apparent that the accuracy will be still be obscure due to lack of

sufficient ‘correct’ data.



REVIEW OF THE ISSUES AND RECOMMENDATIONS:

(i) THE V42 GAS MANAGEMENT SYSTEM:

With an assured savings of £23,000, the BMS outranks all others on the

list due to its reliability. Additionally, we also get an assurance of

reimbursement if companies fail to meet their promise. There can’t be a

better reason to invest; more importantly when it’s within the

companies guidelines. More importantly, it provides a cheaper platform

for a Building Management System which has dealt in with more details

in the ‘Lighting’ section.

(Vickers Electronics)

‘Go forward with the project’

(ii) BOILER PROJECTS:

Provided all conditions of implementation are ideal, with a spectacular

savings of at least £76,000 pounds each year and an anticipated payback

of just 62 weeks, the proposed boiler project ranks second on my list of

recommendations.

PROJECT INVESTMENT SAVINGS PAYBACK (weeks)

AUTOMATIC TDS

£2,000 £4,100 25

HEAT RECOVERY (TDS ONLY)

£8,000 £12,000 35

CONDENSATE RECOVERY

£80,000 £61,000 69



OVERALL £90,000 £77,100 62

Table 1.17- Summary of all the proposed projects related to boiler

Moreover, contractors like Spirax Sarco promise to reimburse all the cash if they

fail to meet their promise; which additionally insures our investment. Other small

improvements like ‘COSPECT’ from TLS, pressurised condensate tank and others

could be made so as to improve the performance and reduce the maintenance

costs.

COSPECT®’s built-in strainer, Super Cyclonical Effects Separator (SCE) and Free

Float® steam trap help prevent scale, rust and condensate from entering the

pressure reducing valve (PRV) or reaching the important interior parts. In

particular, the cyclone separator forcibly removes 98% of the condensate from

the flow at the inlet side, thereby greatly reducing condensate-induced erosion of

parts such as the main valve. While the standard service life of a PRV for steam is

often less than a few years, many TLV COSPECT® users are still using their

COSPECT® PRVs more than 10 years after installation. Such long service life is a

testimony to COSPECT®'s effectiveness in countering scale and condensate, some

of the most common sources of problems for PRVs in steam systems.

(COSPECT, TLV)



Fig. 1.18- Cospect reducing the batch process time


(iii) SWITHING SPACE HEATERS FROM HP SUPPLY TO LP:

Talking of the advantages first, theory suggests that there is a scope of

making profits through switching the space heaters from HP to LP

supply. Also, there is a scope of reviewing the position of space heaters

so as to draw the maximum benefits. With the pending issues with the

gas infrastructure on site, it could be daunting to conduct an exact

savings analysis. However, it is certain that we will save cash, a

substantial amount. The payback period, as seen above, is much less

than the ‘two year’ threshold. But it may be worthwhile to consult the

contractors and be advised on the amount of gas actually flowing

through the pipes. They usually have orifice meters, gauges and small

test stations to predict the approximate flow rates and volumes. The

implementation might have an adverse impact on the production for a

considerable amount of time. Willingness of other offices to get involved

in the project will always remain a question posing a major problem for



the implementation; doing it internally might sound like an idea. But

looking at it over a long run, I envisage huge savings and hence would

recommend to:

‘Advance this project’

(iv) INSULATION ISSUES:

After a thorough investigation, it was found that the insulation of the

factory is okay and has recently been reviewed in the last quarter. The

detailed specs of the roof that covers the majority of the offices and the

production area are summarised below:

A new over clad system comprising of ‘’Ashgrid’’ spacer bars fixed

to the existing structure, 83 mm fibreglass quilt insulation and

covered with a 0.7mm Platisol coated steel cladding sheet.

Where glazing has been removed, a new GRP factory assembled

roof light system with a class 3 fire rated 2.44 kg/m2 (with white

tint) outer sheet and class1 1.83kg/m2 inner liner was instated

In ridges-0.7mm Plastisol coated steel flashing, including profile

fillers where necessary

In all gutters- 3mm aluminium gutter complete with all necessary

stop ends and outlets

There are some parts, especially towards the farther end of the factory

that still needs better roof insulation. But I was advised that it has

already been considered and due to the heavy costs involved, the

progress is being made in parts.

‘No action needed at the moment’



(v) DESTRATIFICATION FANS:

Following the rearrangement of the factory a few years ago, the lighting,

space heating and the destrat fans should have been rearranged. But

this was ignored then; thereby reducing the heating efficiency. But the

good news is that, it is already in the company’s prospect to redo 60% of

the wiring of the factory; the cause being electrical fatigue, the issue

can’t be brushed off for safety reasons. So, during this project, the

destart fans could be relocated to the desired positions with little or no

investment costs.

‘No action needed at the moment. But this has to be reconsidered

during rewiring project’.

(vi) CURTAINS IN THE SHOP FLOOR:

It’s good practice to have curtains around the warm zones in the factory

so as to not let the heat escape the place. This is advantageous is winter

as you may not need a heater in the region. But during summer, this has

got detrimental implications. The hot air is trapped in the region making

the place unbearably hot and unfavourable to work in. However, the

other parts still need heating as they are relatively cold. So, my proposal

would be introduce some sort of rolling mechanism through which the

curtains could be rolled up during the summers and vice versa. This is a

more efficient way to solve the heat strata issue. Intuitively, it won’t

cost a fortune to do this. But the benefits will become apparent from

the bills.


(vii) CUTTING BOILER COSTS THROUGH RO:

Poorly maintained boilers and hot water systems can be high cost items,

especially in terms of upkeep and increased power consumption. These



costs can, however, be significantly reduced by treating boiler feed

water before use, usually through some form of water purification or

chemical dosing system. Typically water purification systems for low

pressure boiler feed, for example, have been based on very simple ion-

exchange softening plants, but for boilers that run at high pressures

greater water purity is required. In this instance the water purification

system typically employs the use of reverse osmosis. Although reverse

osmosis technology has been proven and is generally understood by

most building and plant engineers, what is often overlooked is the

importance of long term planning to optimise the efficiency and

performance of each system. Indeed, from some suppliers there is often

little on-going support to help customers maximise the return on their

investment. Reverse osmosis water purification systems are increasingly

being employed across many industries and the capabilities of these

systems to clean water are impressive. Pressurised feed water is passed

through specialised semi-permeable membranes to remove inorganic

ions and dissolved organic contaminants, typically eliminating over 99%

of micro-organisms. The latest membrane elements used in reverse

osmosis systems provide high levels of flow at lower operating pressures

and their exceptional performance not only results in close on 100%

purity but also cuts the cost of purification, since pump speeds, and thus

energy demand, can be significantly lowered. Variable speed drives for

purification units can cut costs yet again, as they enable the speed of

each unit to be matched exactly to the output demands of the water

treatment system. But, it’s worthwhile assessing the benefits offered by

the RO system against the investment costs and the maintenance

involved. However, to minimise running costs and extend operating life,

the reverse osmosis system needs to be effectively managed with a

consistent approach taken to system operation and preventative

maintenance. The effectiveness of a reverse osmosis membrane can be

compromised by the accumulation of scale, organic contamination or



biofilm. Even though the rate of build-up can be reduced by good

system design, tailored pre-treatment and by pre-programmed

automatic flushing of the system installed specifically to minimise the

build-up of contaminants before they adhere to the membrane surface,

the membranes will eventually need to be cleaned. The period between

cleans will depend on many factors, such as incoming feedwater quality,

the pre-treatment employed and the duty on the RO plant itself. Beyond

membrane maintenance, mechanical units such as pumps, valves and

pipework should be inspected at regular intervals, with seals,

diaphragms or other components that are prone to wear being replaced

before they begin to fail. .With routine cleaning and maintenance, a

reverse osmosis system will deliver consistent levels of performance,

efficiency and reliability, preventing unexpected downtime and

component failures. Most of the benefits from a RO system are achieved

from the savings through water and waste disposal. The maximum

potential of the system is harnessed in a beverage industry, where

water treatment and high degree of purity are of paramount

importance. Taking the maintenance, investment cost and the paucity

of time into consideration, it might not be feasible to conduction a

savings analysis on the RO at this point. We are anyway looking at a

savings of more than £75,000 from the boiler itself through the above

stated boiler projects. Implementing the RO system will make the boiler

more redundant and will only aggrandize the process. So, the project

should be on a stand; at least until the time the actual profits from the

‘Heat Recovery System’ have been realized. I would recommend to:

(Cutting Boiler Costs with RO, Purite)

‘Not advance this project until the ongoing boiler projects have fully

paid for themselves within the promised duration’



LIGHTING

PROJECTS



INTRODUCTION TO THE LIGHTING AT CONTITECH:

According to a recent internal survey for lighting by the assistance of the

‘Electrical Duty Holder’, Mr Malcolm Smethurs, 60 % of the factory needs rewiring

for electrical safety and compliance reasons. On an average Contitech, Wigan

pays more than £370,000 annually towards electricity bills; which is horrendous

but is imperceptible due to size of the factory and nature of the business.

(Electrical Survey, August 2013, Smethurs Electricals)

The electrical wiring in the factory is relatively simpler as compared to gas. As can

be seen from below, electricity is fed into the factory from four substations

through the distribution boards which further control either the machinery

directly or the lighting distribution boards. We have a total of 120 distribution

boards of which only 10 are deployed to control the lighting. A schematic

representation of the network has been provided below for better understanding.

The distribution boards operate using KNX protocol, which is a globally used

electricity control systems language.

In efforts to reduce the consumption on lighting, two projects have only been

proposed in the following sections. It could be challenging to conduct a payback

period analysis based on the little information available and no contractor quotes.



Figure 2.1- Contitech Lighting Network

LIGHTING

DISTRIBUTION

BOARD

LIGHTING

SWITCHES

SWITCHES

LIGHTING

DISTRIBUTION

BOARD

DISTRIBUTION

BOARD

SUB STATION



LIGHTING ACTION PLAN

As a preliminary attempt to save energy on lighting, a ‘lighting’ survey was

conducted to determine the ‘real needs’ of the factory. Based on the survey

conducted by ‘Smethurs Electricals’, and with the assistance of Mr Malcolm

Smethurs and Mr Dan McCloughlin, two plans were designed. The former depicts

the current lighting and wiring in the factory, where as the latter entails the

‘actual lighting needs’ in the factory. In other words, it shows the ‘needless lights’

that could be taken out. The latter was a follow up of a full-fledged survey of the

factory with the line managers of the individual zones discussing their needs.

Zone based recommendations on efficient utilisation of the light resources have

been drawn in a tabular form by thoroughly examining the shift patterns, access

patterns, maintenance needs and ‘Health and Safety’ requirements.

**The plan mentioned below is attached to the ‘Appendices’ section at the end.

**N.B. - The following action plans excludes the warehouse as it was advised

(by Mrs Trudy Crowther) that it will be undergoing a turnover in the near future,

and that it was contrary to the point to analyse the lighting in that area.



ZONE (in-charge) AREA/ SECTION OPERATIONAL PATTERN/ISSUES

ACTIONS

AUXILIARY (MR MARTIN ATKINS)

PRESSURE SLEEVE STORAGE

24*6 under use. But not accessed at all times

Use motion sensors.

Few dimmers shall be beneficial.

ALL OTHER AREAS IN THE AUXILIARY (expect the specific areas mentioned below)

MON-FRIDAY: 0600-2200 SAT: 0600-1200

Timing the switching patterns.

Heavily accessed during all times of operation

No dimmers/ motion sensors needed.

*Few lights can be removed

*Revision of positioning needed

BUILDER 6 Only operated during the days

Day light sensors may be useful

*2 lights can be removed

*Revision of positioning needed

REAR SIDE (between autoclave and compressors)

Seldom accessed *Revision of positioning needed

*3 lights can be removed

Motion sensors can resolve the issue

REAR AUXILLARY STORAGE

Rarely accessed Motion sensors

*Centralisation of lights needed

AUTOCLAVE Once/ twice a day *1 additional light needed- properly oriented

MAINTENANCE (MR PAUL SNELLGROVE)

ENGINEERING WORKSHOP

24*6 (Monday to Saturday) Lightly accessed

Timing the zone Motion sensors Lights need lowering

PUMP HOUSE 24*6 (Monday to Saturday) Lightly accessed

Motion sensors

BOILER HOUSE 24*6 (Monday to Saturday) Lightly accessed

Motion Sensors

RND AND MAINTENANCE OFFICES

Monday to Friday: 8am-5pm

Timers *3 redundant lights over the roof of the maintenance can come



out

**Maintenance team should have autonomous access to the lighting in all zones at all times to carry out the maintenance works (RPM)

COMPOUNDING, GOODS INWARD AND ROTA CURE (MR BARRY URNSWORTH)

QUARANTINE AREA Monday to Friday: 6am-4pm

Timers *One light can come off Occasionally accessed on

Saturday mornings

BIAS CUTTER PASSAGEWAY


**2 lights need repositioning

MANDREL SLEEVE STORAGE


*3 Lights can come out Motion Sensors

FOLCKING MACHINE AREA


No changes

LAB MILL Monday to Friday: 6am-4pm

*2 lights can be on motion sensors

CORD STORAGE 24*6 Lightly accessed

Motion sensors

GOODS RECEIVING STORAGE


Day light sensors Timers Centralisation of fittings necessary *1 light can come out

MEZZANINE FLOOR STORAGE

Seldom accessed *50% of the fittings can come out Rest could be on motion sensors

CUSTOMER RETURN STORAGE

Lightly accessed during day light hours

Day light sensors Motion sensors Timers

ROTA CURE Mon-Fri: 6am-10pm Timers 3 big obsolete lights can come out

AUTOCELL (MR STEPHEN HAMLETT)

SLITTER AND CURING

Monday to Friday: All day Saturday, 2pm- Sunday afternoon

Motion sensors on Girder ‘K24’

EPDM STORAGE Lightly accessed on weekdays

Motion sensors on the back-wall storage region

LABEL STORE Rarely accessed 2 obsolete lights over the roof can come off

OFFICES MAIN ALLEY 24*7 Daylight Sensors Deflectors can be used on the lights



MR IAN JONES’ OFFICE


Motion sensors Timers

ACCOUNTS Monday to Friday: 8am-4pm

Timers Motions sensors on individual fittings to provide more flexibility.

CUSTOMER SERVICE OFFICE


*3 sets (12 lights) can come out

Rest could be on individual motion sensor

ENTRANCE SUBSTATION (MR MALCOLM SMETHURS)

Rarely accessed *1 light can be taken down Motion sensors

CELL 3 (MR NEIL STOUT)

BUILDER 3 Sunday 2pm to Saturday 2pm. Heavily accessed

No changes

CURING Sunday 2pm to Saturday 2pm. Heavily accessed

*1 more light needed

INSPECTION Monday to Friday: 6am-4pm

Time the zone

SLIT BELT STORAGE AREA

Lightly accessed from Sunday 2pm to Saturday 2pm.

Motion sensors

CELL 5 (MR NEIL STOUT)

MINI SLITTER Lightly accessed Motion sensors

ALL THE BUILDERS Lightly accessed Motion sensors

MAINTENACE LIGHTS MOUNTED ON WALLS

Rarely used Motion sensors

ALL OTHERS Sunday 2pm to Saturday 2pm. Heavily accessed

No changes

MAIN CORRIDOR - Day light sensors

*- Please refer to the plan



KNX BUILDING AUTOMATION

WHAT IS KNX?

In order to transfer control data to all building management components, a system is required that does away with the problems of isolated devices by ensuring that all components communicate via one common language: in short, a system such as the manufacturer and application domains independent KNX Bus. This standard is based upon more than 20 years of experience in the market, amongst others with predecessor systems to KNX: EIB, EHS and BatiBUS. Via the KNX medium to which all bus devices are connected (twisted pair, radio frequency, power line or IP/Ethernet), they are able to exchange information. Bus devices can either be sensors or actuators needed for the control of building management equipment such as: lighting, blinds / shutters, security systems, energy management, heating, ventilation and air-conditioning systems, signaling and monitoring systems, interfaces to service and building control systems, remote control, metering, audio / video control, white goods, etc. All these functions can be controlled, monitored and signaled via a uniform system without the need for extra control centers. (What is KNX, KNX ASSOCIATION)

Lighting Blinds & Shutters

Security Systems

Energy Management

HVAC Systems

Monitoring Systems

Remote control

Metering Audio/Video Control

White Goods

Fig 2.2- What we can control with KNX



WHAT ARE WE AFTER? ANSWER- ETS 4 PROFESSIONAL:

ETS means Engineering Tool Software; a manufacturer independent configuration tool Software to design and configure intelligent home and building control installations with the KNX system. ETS is a software, which runs on Windows© platform based computers. As we

know our ‘Lighting distribution boards’ are equipped with the KNX system, ‘ETS’

sounds like a notion. The use of ETS offers ‘n’ number of advantages like

1. Guarantee of maximum compatibility of ETS software with KNX- Standard 2. All product databases with certified products from all KNX manufacturers can be imported in ETS 3. Backward compatibility of ETS to product data and projects of earlier ETS versions (until ETS2) saves your working results and allows editing. 4. Everywhere in the world all planners and installers use one and the same ETS tool for every KNX project and for every KNX certified device. Reliable data exchange is therefore guaranteed.



Sample Model Series

Sensing Types Mounting Types

Temperature Humidity Motion CO

2 CO

Smoke Flow and Pressure

Wall Duct and

Other

FlexStat X X X X X

NetSensor X X X X

CAE-1003/1103 X X

SAE-1000 X X X

SAE-1100 X X X

SSE-1000/2000 X X X

SSS-1000 X X

STE-1400 X X X

STE-5200/5300 X X

STE-6000 X X

THE-1xxx X X X X

TPE-1xxx X X X

Fig 2.3- KMC’s Sensors

The ETS4 Professional is the powerful successor of ETS3 and is back compatible to

the previous versions of ETS. Along with its docility it also offers a wide range of

services like:

Lighting control (switching; dimming; “mood lighting”)



Lighting can be controlled through lighting sensors like ESENZETM by STEINEL. It cuts down the wastage of energy by diminishing the intensity by 15-40% and offering a flexible on/off switching pattern.

Lighting can also be controlled through ‘timed controllers’ like KNX’s ‘BERKER Series’ and ‘HAGER Controls’ and ‘DALI Gateway’

(Lighting Automation and Green Building Materials, PAMMVI)

Shading control (shutters; blinds) Group and central positioning offered Sun tracing, preset positioning, and wind and rain protection Safety modes Operated through the ‘SMI Gateway’

Heating: individual room temperature control by controllers like KMC’s ‘STE

6000 series’, ‘Flexstats’ and ‘Net Sensors’ Control of radiators, thermal units, boilers, coolers and fans Humidity and be controlled by sensors like KMC’s ‘THE-1XXX series’

and many more.

Ventilation and air-conditioning: CO2 levels can be controlled by KMC’s ‘Flexstats’ and ‘SAE 1000

series’ CO levels can be monitored by the ‘SAE 1100 Series’ Smoke levels can also be monitored though KMC’s ‘CAE-1003/1103

Series’

Access & security presence detection burglary and fire detection and alarm presence simulation panic switch

Energy management consumption metering; load shedding flow rates and pressure can be monitored by KMC’s ‘SSE-1000/2000

Series’, ‘SSS 1000’ and ‘TPE 1XXX Series’



Comfort functions and intelligent control across all applications central user control combined scenarios intelligent process control

Remote control and remote maintenance e.g. via phone or Internet

Interfacing to complementary or peripheral systems white goods; supervision consoles; facility management; audio;

multimedia

(KMC Sensors: Sensing your needs, KMC Controls)

KMC also claims that all settings when properly configured, complies with ‘ASHRAE Std. 62.1- 2010’ and follows guidelines by ‘Portland Energy Conservation Inc. (PECI)’

Fig. 2.4- KNX Products and Sensors

(KNX Certified Products, KNX)



LINKING THE EXISTING LIGHTING INFRASTUCTURE TO THE EMS

As previously mentioned, to be able to perceive the savings, a ‘foolproof’ Building

Management System is inexorable. But assuredly, this is remarkably expensive.

This project proposal entails to extract the most out of the ‘V42 Vickers System’

which has previously been discussed in the GAS section.

‘V42’ is well known in the UK for its advantages and docility. It offers us to control

any 42 units through an equal number of ports. Each heater on site can be linked

on to one port; this reserves 17 ports. This still leaves 25 ports unoccupied.

Following the ‘Lighting Survey’ conducted in August 2013, more about the lighting

and wiring is more known now than ever. Judicious use of this information can

bear great consequences.

So, the quick, cheap and relatively easier fix is to make use of the information

gathered from the survey to rewire all the lighting on site to a maximum of 25

units; we have a lot more ‘Lighting Distribution Boards’ on site which are

interlinked. Moreover, a ‘rewiring’ project is already in company’s plans for the

near future due to political reasons. So, most of the cost of the rewiring due to

incorporation of the existing lighting with the ‘Gas Management System’ will be

subsumed under the cost proposal outlined for the preplanned ‘rewiring project’.

This explains that there can’t be a better time to do this.

**N.B. - The technical aspects, the way the system works and other non

technical details have already been covered in the ‘GAS’ section and will not be

covered again in this section. Please refer to Pg. 33 for more information on the

system.



OPERATION:

It has been found out from the ‘Electrical Duty Holder’ that this is practicable. So,

presuming that the above proposals are carried out without any alteration, the ‘V-

42’ should now control all the space heaters in Contitech along with the complete

lighting.

WEIGHING THE PROS AND CONS

PROS CONS

More control over the lighting in factory from a single unit

No automation, no motion sensors. Hence, no intelligence.

Zones could be timed No control over flow rates, pressure

Savings of about 6% on electricity bills

Compatibility with the existing KNX system is dubious

Fig 2.4- pros and cons of the proposed project



SAVINGS:

It’s really challenging to conduct an exact savings analysis based on the amount of

information we have at this point. We are falling short of quotes. Hence,

conducting the payback period analysis is ‘senseless’. However, ‘V42’ envisages a

savings of 6% on the total electricity bills through the docility of switching the

lights on/off. But they don’t guarantee it!!! Much of this is also related to how the

lights are wired and if everything could be controlled by the ‘V42’. All these

information are skeptical at this point. Nonetheless, just for a crude idea of

savings through this easily managed switching pattern, a savings analysis has been

provided below based on ‘V42’s’ specs:

Looks diminutive? Yes. But here is a ‘brainer’!!



AMELIORATING PROFITS:

The next proposal is to meet the requirements of various zones, as outlined in the

former sections, through an ‘internal project’. All the desired sensors could be

purchased from the ‘registered KNX suppliers’ (a list of the registered KNX

suppliers in the UK has been enclosed to the ‘Appendix’ at the end) and could be

fitted ‘internally’; this makes both economic and political sense. As previously

mentioned, there can’t be a better time to do this as we are already under way

for a ‘rewiring project’. It’s not just irrefutable that we’ll be saving ‘opulence’

through motion and daylight sensors but also we’ll be going greener through the

use of ‘smoke, CO and CO2 sensors’; this will be a great step towards the ‘ISO

15001’ accreditation which is already under the company’s objectives for

forthcoming years. It’s however impracticable to conduct an exact savings and

payback period analyses primarily due to the paucity of time, and also partly due

to the reasons mentioned previously.



CONCLUSION:

It’s a ‘no brainer’ that Contitech’s energy bills are astounding. So, at least few of

the proposed projects need to be implemented to cut the costs on energy. With

the fuel prices soaring each year, these energy issues become more exigent.

Carefully examining the work carried out, it’s being suggested that all the

projects, if planned to be undertaken, should be in steps and not ‘in a go’; the

reason being redundancy. For example, you are investing on two of the proposed

gas projects- say, ‘Gas Management System’ & any of the boiler projects.

Evidently, there will be a commitment associated with all the supplier-quotes.

Hypothetically, if the former guarantees 20% savings and latter guarantees a 30%

on the overall consumption and we note that we have saved a 40% on the total

consumption, it’s obscure where the actual savings came from. Both the suppliers

won’t payback the difference as they would claim that it’s their project that saved

us cash. So, it is a modest idea to invest in a project, wait until the payback and

commitment are met, and then go on to another. Keeping the upcoming winters

and the amount of information already gathered in mind, it’s recommended to do

the HP/LP switching project before the winter sets in; it’s expected to save us

about £40,000. Gas Management System and linking it with the lighting may also

be considered concurrently. Albeit utmost care was taken while conducting the

savings analysis, there hasn’t been any contractor quote to check it against. So,

it’s highly recommended to get contractor quotes to check the numbers, even

though it’s decided to do it ‘internally’. Having proposed all the projects, it’s

admitted that ‘‘There is always room for improvement’’ and there are more

energy saving techniques like ‘Combined Heating Power’, ‘Solar Panels’, and many

more. These weren’t included in this proposal as it didn’t find it to the scope of

the company when the project kicked off- ‘Quick Wins through minimum

investments’. Nonetheless, if ‘Continental’ decides to revisit their norms on

‘investment and payback’, these might be the kind of projects the company might

be look. They have got long terms benefits on energy savings, branding and

environment, and also highlight the corporate social responsibility but entail huge

investments. The call will be management’s.



APPENDICES

1. Boiler Specs

2. Boiler Igniter Specs

3. Spirax Sarco Contractor Quotes

4. Tecnhiheat Plant Services Gas Survey

5. Building insulation and roofing plan

6. List of registered KNX suppliers

7. Contitech utility bills- Gas and electricity

8. Gas spread sheet (original)

9. Vickers V42 System quotes (not finalised)

10. Lighting Plan

11. Renewed Lighting proposal plan



BIBLIOGRAPHY

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